Diesel Forum - TheDieselStop.com - Reply to Topic
'99 & up Upgrades and Aftermarket - 7.3L Engine Upgrading or adding OEM or aftermarket equipment to your 1999-Up Super Duty or Excursion with 7.3L Power Stroke diesel engine. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

Send Trackbacks to (Separate multiple URLs with spaces) :
Post Icons
You may choose an icon for your message from the following list:

Register Now

In order to be able to post messages on the Diesel Forum - TheDieselStop.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


  Additional Options
Miscellaneous Options

  Topic Review (Newest First)
10-05-2018 12:19 PM
Fuel system mods

This was a very popular topic back in 01 and 02. My new 02 truck was quite noisy had a sound like someone taping on a coffee can at idle. So I have done it all, Hutch Mod, DAHL pre pump water separator and filter, Regulated return, changing out the #8 LL injector for an AD and a return to tank fuel cooler. From a noise perspective he most effective thing that actually had positive results was the Regulated Return system, but one should be aware that it drastically increases return to tank fuel temps. Opinions differ because the variables are seasonal as well tank levels. In Alabama summers at 1/4 tank on the interstate my tank temps would get to 170F, with the cooler I rarely see more than mid 130's F. I choose to cool it down, many don't. But at least in cold climates with a RR your wont have to worry about cold fuel as much.
If one does the Hutch mod, which I would again, it's a given you will need a pre pump filter. Get a good system like the poster above has, or one like mine a DAHL 100 and get some additional benefit of actual water removal from fuel, it's in there and the stock filter assembly is worthless.
I probably would not change the #8 LL injector unless I was in there for something else, it made no difference for me except the 250 bucks and sore back.
It was about this time that many people were making mods in their systems that produced entrained air and that seemed to give birth to the air seperators, dang they have always been expensive. I really don't see the need.
10-05-2018 07:13 AM
blue99stroker No need for a sump. The hutch mod goes to the bottom of the tank.

I’m around 400hp with the stock setup and i maintain fuel pressure under load.
10-04-2018 02:19 PM
mcnance865 If you want full kits, look at Irate Diesel Full Fuel system. I think BD Diesel makes one as well.
10-04-2018 11:58 AM
JJEdwards Thanks Guys. Very helpful information. Hutch mod it is then with a Beans sump.

10-02-2018 11:32 PM
Calico5 Blue99stroker has it right.

Just do the hutch Mod, then a full regulated return system, and install pre- and post-pump filtration. This is as good as it gets for these trucks, and will remove any air in the system you need to worry about.

I did an "ITP" in-tank mod's waaay back, then did my own pump/filter setup. It has been in and working for over 10 years. The primary filter block is NAPA unit, and the secondary is from a Cat (has an air bleed valve built-in). Fab'd up the mounting brackets out of aluminum, bolted through frame-rail, and mounted/plumbed the pump in between. Supply line to the engine is -6 Aeroquip TFE hose. The return line from the engine to the tank utilizes the factory steel line.

In addition, I moved the pump back about 3-4 feet (right in front of the tank) so it's not pulling the fuel so far through the puny stock 5/16" line (lots of restriction). Used 3/8-inch "push-lock" line and inverted-flare fittings from the tank to the first filter (only about 30").

It ain't fancy, but it works great...

Posted about the filtering here: https://www.thedieselstop.com/forums/4641346-post9.html

10-02-2018 10:59 PM
DENNY I would agree with Blue99stroker. Once you do the hutch mod (harpoon while the tank is down) you have fixed the foot issue that a air/fuel separation system does not address. I would also do a fuel return system to get air out of the heads. I would not expect to see any real MPG increase with any of the mods, just a better running/dependable engine.
10-02-2018 06:25 PM
blue99stroker No gains, the pumps aren’t very reliable at 60 psi

If you want to solve the air issue you need to do the hutch mod.

It gets rid of the in tank filters and moves the return away from the feed
10-02-2018 05:43 PM

Considering putting in an AIR/FUEL SEPARATION SYSTEM and wondering what everyones thoughts are on them. Are they truly worth the $700.00 long and short term? I've heard they improve performance/HP and save wear on injectors.


Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

For the best viewing experience please update your browser to Google Chrome